NORDSEETAUCHER GmbH - tunneltrade · NORDSEETAUCHER GmbH (N-Sea-Divers) Hyperbaric Tunnel...

NORDSEETAUCHER GmbH (N-Sea-Divers)

Hyperbaric Tunnel Construction and Diving®

and

Work under Hyperbaric Conditions Diving and

Compressed Air Work on TBM’s

Tunnel-Boring-Machines

NORDSEETAUCHER GmbH Hyperbaric Tunnel Construction and Diving®

Nordseetaucher GmbH, Bramkampweg 9, D-22949 Ammersbek, Germany; Tel. +49 4102 23180, Fax +49 4102 231820, Mobile +49 172 4300598 E-mail: [email protected]; Internet: www.nordseetaucher.de

Int. Diving Contractor OffshoreWind Inwater Service®

Hyperbaric Tunnel Construction and Diving®

Water Power Plants Offshore Oil and Gas and Reservoirs Inshore / Inland

Renewable Energies Hyperbaric Tunnel Constructions

Bramkampweg 9 22949 Ammersbek Germany Tel.: +49 4102 23180 Fax: + 49 4102 231820 Mobile: +49 172 4300598 E-mail: [email protected] Internet: www.nordseetaucher.de



Arbeiten in Überdruck Taucher- und Druckluftarbeiten im maschinellen Tunnelvortrieb

Ab einer Tiefe von 40 Metern (4,0bar Überdruck) kommt der Druckluftarbeiter in Bereiche wo es von der Zeit her nicht mehr interessant ist Druckluftarbeiten auf herkömmliche Art auszuführen. Da aber die nächste Generation von Tunnelprojekten immer länger und immer tiefer gebaut wird war es nur eine Frage der Zeit und Gelegenheit den Einsatz von Tauchern für die Arbeiten in Überdruck mit einzubeziehen.

Work under Hyperbaric Conditions Diving and Compressed Air Work in Tunnel-Boring-Machines

Below a depth of 40 metres (which equals 4.0bar over pressure) workers enter a zone where it is no longer effective to carry out compressed air work under conventional conditions. However, because the next generation of tunnels will be longer and deeper than anything we have at present, it can only be a matter of time and opportunity before divers start playing a key role in hyperbaric work.

Trabajos en ambientes hiperbáricos Trabajos de buceo bajo aire comprimido para la construcción mecánica de túneles

Por debajo de una profundidad de 40 metros (equivalente a una sobrepresión de 4,0 bar) los buzos entran en una zona donde ya no resulta efectivo llevar a cabo trabajos en ambientes hiperbáricos bajo las condiciones tradicionales. Dado que la próxima generación de túneles se proyectarán cada vez más largos y a mayor profundidad, era sólo cuestión de tiempo y ocasión el destinar buceadores a los trabajos hiperbáricos.

Работы на глубине под давлением

Проведение строительных работ по прокладке тоннелей начиная с глубины 40 метров и при давлении

4,0 бар становится сложным. Это та граница, когда вести строительство тоннеля традиционным способом становится трудно. Однако, как показывает жизнь, большинство новых тоннелей будет

прокладываться на все большей глубине и они будут еще длиннее. Это только дело времени, когда к этим работам будут привлекаться специалисты - водолазы.



Reference List for Hyperbaric Work Diving, Compressed Air, Mixed-Gas Maintenance and Repair Work on Tunnel-Boring-Machines (TBM’s) 1994 Europipe I and II, North Sea-Germany 1997 Bewagtunnel, Berlin-Germany 1997 - 2000 S-108 4th tube River Elbe Crossing, Hamburg-Germany 1998 - 2002 S-137/38 Westerschelde Tunnel, Zeeland-The Netherlands 1999 M-498 Mompas, San Sebastian-Spain 2000 - 2001 S-152 Wesertunnel, Nordenham-Germany S-149 Airporttunnel, Zürich-Switzerland S-140 Bahn 2000-Thalwil, Zürich-Switzerland 2000 S-127 Socatop, Paris-France M-532 Crosswaytunnel-4th tube of River Elbe, Hamburg-Germany S-110 Fernbahntunnel, Berlin-Germany 2001 M-611 Neva-Crossing, St. Petersburg-Russia 2001 - 2002 S-164 Lefortovo Tunnel, Moscow-Russia S-150 Sophiaspoortunnel, Rotterdam-The Netherlands S-168 Pannerdenschkanaal, Arnhem-The Netherlands 2002 S-205 Peristeri Metro, Athens-Greece M-518 TENP Los 4/5, Lörrach-Germany S-170 Deep Sewerage, Singapore 2002 - 2003 S-192 CTRL-Thames Tunnel, London-England S-175 Oenzbergtunnel, Switzerland S-200 Herrentunnel, Lübeck-Germany



2003 S-209 Aanlegspoortunnel, Antwerpen-Belgium S-185 Heathrow Airport Tunnel, London-England S-187 Metrotunnel, Caracas-Venezuela 2003 - 2007 S-250 Silberwald, Moscow-Russia S-290 Silberwald, Moscow-Russia 2004 S-127 Socatop, Paris-France S-242 Metro Line 3, Guangzhou-China 2004 - 2005 S-252/53 Smart Tunnel, Kuala Lumpur-Malaysia S-238 Metro Line 1, Napoli-Italy M-929 Kura West River Crossing, Azerbaijan 2004 - 2007 S-221 Metro Line 9, Barcelona-Spain 2004 - 2006 S-255 Metrotren, Gijon-Spain 2005 M-000 Medientunnel Leipzig-Germany 2005 - 2006 S-258 Flughafen S-Bahn Hamburg-Germany S-302 Metro de Madrid-Spain 2006 M-675 La Malata, A Coruña-Spain S-327 Harbour Tunnel, Durban-South Africa S-320 Almatymetrohurylys, Alma Ata-Kasachstan M-614 Chateau d’Olonne, France S-324 Metrotunnel, Ankara-Turkey S-325 Metrotunnel, Istanbul-Turkey 2006 – 2007 S-331 Fernwärmetunnel, Copenhagen-Denmark S-314 Stadtbahn Köln Los Nord, Cologne-Germany S-321/22 Stadtbahn Köln Los Süd, Cologne- Germany S-127 Socatop, Paris-France S-328 Metro Strogino, Moskau



2007 S-317/18 Traffic Tunnel Shanghai-China M-971 Wuhan, China M-1016 Santander, Spain S-264/65 Katzenbergtunnel, Germany 2006 -2008 S-260 Metrobus, Brescia-Italy S-326 City Tunnel Leipzig-Germany S-340/41 Citytunnel, Malmö-Sweden 2007 -2008 S-334 U-Bahn Linie 3, Munich-Germany S-389 Thun, Switzerland S-227/28 Metro Esfahan-Iran 2008 M-1198 Doha-Qatar, Persian Gulf S-407 Water Tunnel Shanghai-China M-518M Pescanova Fishfarm, Mira-Portugal S-358 Yellow River Tunnel, China 2007-2009 S-352 H3-4 Münster / Wiesing-Austria S-381 H8 Jenbach-Austria 2008-2009 S-349/50 Nanjing Yangtze River Crossing-China M-1193 RS1 H8 Jenbach-Austria RS2 H8 Jenbach-Austria S-419/20 Finnetunnel, Erfurt-Germany M-254M Sammler Ost, Hamburg-Germany 2009 S-307/08 Metro Tunnel Singapore S-408 Water Tunnel Shanghai-China Emstunnel, Emden-Germany NFM Railway Tunnel Schlüchtern-Germany RS3 H8 Jenbach-Austria; RS4 H8 Jenbach-Austria RS5 H8 Jenbach-Austria; RS6 H8 Jenbach-Austria RS16 H8 Jenbach-Austria; RS18 H8 Jenbach-Austria S-477 CREC Tunnel Foshan-China S-464 Diabolo Tunnel Brussels-Belgium S-354 Metro Line 4 Budapest-Hungary 2008-2010 S-440 U4 HafenCity, Hamburg-Germany



2009-2010 S-227/28 Metro Esfahan-Iran S-423 Metro Line 3, Cairo-Egypt M-1061 Sea Outfall, Salvador de Bahia-Brasil M-907M Großrohrschirm Zürich-Schweiz S-221 Ute Gorg, Barcelona-Spain S-444 Ute Trinidad, Barcelona-Spain 2010 S-246 Hallandsås, Förslöv-Sweden S-532 LocoBouw, Antwerpen-Belgium M-1317 Sammlers Ost 2.BA, Hamburg-Germany M-0000 Düker Brunsbüttel-Germany M-518M Großrohrschirm Zürich-Switzerland S-362 Ute Ave Girona, Girona-Spain M-1419 Opal Peene Querung Anklam-Germany M-0000 Maindüker Schweinfurt-Germany S-509 Metro Tunnel Wuhan-China S-525 Metro Tunnel Sofia-Bulgaria 2009-2011 S-227/28 Metro Esfahan-Iran 2010-2011 S-491 Wehrhahn-Linie, Düsseldorf-Germany S-451 Tunnel Weinberg, Zürich-Schweiz S-547 Kaiser-Wilhelm-Tunnel, Cochem-Germany M-1186 Sanitary Drainage Networks, Jeddah-Saudi Arabia S-452 ATUBO Biel-Schweiz S-551 Nuclear Tunnel Project Taishan-China 2011 S-546 Metro B Lyon-France M-1455 CFPP Kraftwerkstunnel W.-haven-Germany S-642 Wisla River Crossing, Warsaw-Poland S-550 Railway Tunnel Shenzhen-China S-554 Metro B Rom-Italy M1096 Zürich-Oerlikon-Schweiz S-618 West Island Tunnel-Hong Kong S-502 Lake Mead, Las Vegas-USA 2010-2012 S-544/45 XFEL Tunnel, Hamburg-Germany NFM Railway Tunnel, Beijing-China 2011-2012 S-630/31 Mei Lai Road to Hoi Ting Road Tunnel-Hong Kong S-597/98 Metro Hangzhou-China



2011-2014 S-550 Railway Tunnel Shenzhen-China S-630/31 Mei Lai Road to Hoi Ting Road Tunnel-Hong Kong 2012 S-644 Metro Warsaw-Poland S-636 Metro Hangzhou-China S-668 Road Tunnel Nanjing-China S-324 Metrotunnel, Ankara-Turkey S-666 Traffic Tunnel Shanghai M-663M Drainage Tunnel Catania-Sicilia 2012-2014 CCCC Nanjing Weisan Tunnel-China S-623/24 Railway Tunnel Shenzhen-Hong Kong S-731 Crossrail Tunnel London-UK S-683 Railway Tunnel Nanjing-China 2013 S-605 Metro Singapore S-569 Changjiang Xi Road Tunnel Shanghai 2013-2014 M-1535 Corrib Pipeline Tunnel Ireland Emscher Tunnel Germany M-1186 Sanitary Drainage Networks, Jeddah-Saudi Arabia S-788 Metro Tunnel U5 Berlin-Germany S-762 Eurasia Tunnel Istanbul-Turkei 2014

DEEP SEA Tunnel Diving Helmet



Work under Hyperbaric Conditions Diving and Compressed Air Work in Tunnel-Boring-Machines

Below a depth of 40 metres (which equals 4.0bar over pressure) compressed air technicians enter a zone where it is no longer effective to carry out compressed air work under conventional conditions. However, because the next generation of tunnels will be longer and deeper than anything we have at present, it can only be a matter of time and opportunity before divers and compressed air technicians start playing a key role in hyperbaric work. High groundwater head is a major challenge for tunneling in soft ground and weak rock. It has a strong impact on design and operation of Tunnel Boring Machines (TBMs) in order to prevent excessive groundwater inflow, to ensure face stability and to enable access to the cutterhead for maintenance, which can lead to an increase of the required construction period and budget. Designers should keep this in their mind when planning a tunnel alignment.

The 4th River Elbe Tunnel was a milestone in Slurry-TBM tunneling due to the large TBM diameter of 14.2 m, low cover of as small as 7 m and high groundwater pressure of up to 4.5bar. The southern section of the 2.561 km long tunnel was excavated in glacial deposits consisting of sand, marl and boulders, while more cohesive

ground such as marl and clay with sand lenses and boulders was present on the northern tunnel section. Frequent interventions for cutterhead maintenance were necessary due to presence of abrasive soils. Severe wear was observed on excavation tools and on the backside of the cutterhead which had to plough through accumulated spoil at the bottom of the excavation chamber. Thus intensive and time consuming repair works (6 weeks) were required under compressed air. At the deepest point of the river crossing, the crew had to enter the excavation chamber and work under compressed air up to 4.5bar.

In total 10,920 work hours were spent under regular compressed air at pressures up to 4.5bar by the engineers, diver and technicians during the 4th River Elbe Construction In total 2,738 man interventions were performed, 237 of them at pressures >3.6bar. In total 21 cases of decompression illness were reported, all of them occurred at pressures < 3.6bar.



The 4th River Elbe tunnel was the first project where a rescue could be completed by connecting a NATO flange to the compressed air lock on the TBM to enable transport of injured personnel under compressed air pressure to a shuttle for pressurized transport the surface. Fortunately it was not necessary to use it.

The 1.640 km long twin tube Wesertunnel crosses the river Weser north of Bremen, Germany. A Slurry-TBM ( 11.71 m) was used to excavate the tunnel in glacial deposits. The glacial soil consists of poorly graded and partly very loose cohesion, less sand with hard granite boulders, and very soft to soft clay and peat in shallow areas. Below the river, plastic clays were found to have mainly stiff to hard consistency reaching shear strength values of weak rock.

The tunnel invert’s deepest point was 40 m below sea level. Due to tidal influence of the North Sea the water level of the river was typically between +/-2 m above/below sea level and reached in maximum +5.2 m above sea level. Along the tunnel route, groundwater head encountered at tunnel invert was typically in a range of 2.5 to 4.0 bar and reached a maximum of 4.5 bar at storm tide. Maintenance under compressed air was performed at up to 4.5 bar air pressure for works at the cutterhead and up to 5 bar for works at the stone crusher. Additionally divers were used to work within the bentonite slurry under pressure of up to 5 bar. Regular compressed air (no mixed gases) and oxygen decompression were successfully used. In total 5.000 h of compressed air works and a total of 1.400 man interventions were performed while 600 of them were under pressures exceeding 3.6 bar. Only 15 minor cases of decompression illness were reported, all of them under pressures less than 3.6bar.

The 6.6 km long Westerschelde Tunnel is the first tunnel project where saturation diving technique was used for excavation chamber interventions. The twin tube tunnel was excavated by two Slurry-TBMs (Ø 11.33 m). Ground conditions consist of medium to fine quaternary sands within shallow sections and a massive formation of tertiary stiff clay on a length of approx. 2 km. Dense tertiary sands are found below the clay within the deepest tunnel section.

At the deepest point the tunnel invert is at a depth of 60 m below sea level. The water level was typically within a range of +/- 2.5 m above/below sea level and reached about +4.0 m in maximum. The tunnel cover was in a range of 28 m to 40 m.



When Nordseetaucher GmbH was asked to cooperate on this project to build two tunnels under the Westerschelde in the Netherlands, we didn’t hesitate a moment, knowing that it would be an ideal opportunity to put to use the skills and expertise we had gained during our 4th Tube of the River Elbe Crossing and the Wesertunnel, Germany contracts. However, the problems we could expect to face were on a slightly different scale. In the 4th Tube of the River Elbe Tunnel we were working under pressures of up to 4.5 bar, while work in the Wesertunnel was carried out at 5.0 bar. The brief for the two tunnels of the Westerschelde Tunnel Project called for us to work at pressures of up to 8.5bar. It is impossible to work at 8.5bar pressure with compressed air, because the nitrogen contained in breath causes narcosis. Accordingly, from the very start we planned to work using mixed gases. For several decades, a number of methods and procedures have been tested and applied in international commercial offshore diving which can also be used in machine-driven tunnel construction projects carried out in hyperbaric pressure in excess of 5.0bar.

For instance, the use of mixed gas. These gases are a mixture of oxygen and various inert gases, blended according to the specific pressure spectrum to allow the divers to work for days and weeks under pressurised conditions (saturation method). At hyperbaric pressures of between 3.0 and 6.0 bar compressed air can be used as working gas with the saturation method, and may indeed be the method of preference in future. In order to use mixed gases safely and successfully, meticulous preparations to the tunnel boring machine and logistical processes are necessary.

Due to the relatively thin clearance above the tunnel it would have been dangerous to lower the bentonite level in the cutterhead chamber, the excavation chamber. Accordingly, specially trained diving personnel were on hand to carry out inspections and tool changes in the event of repair and maintenance work becoming necessary. In total, 6 excursions in saturation were performed with a total saturation time of 40 days. The decompression time was 4 days each time. 10 inspection excursions with mixed gas were performed, in addition to 1.652 hours with compressed air involving 546 man interventions. 5 cases of decompression sickness occurred, all of which were successfully treated in the onsite treatment chamber.



Diving in Bentonite Preparation To allow manned interventions to be carried out in the bentonite, special flanged connections were installed in the pressure walls of the tunnel boring machines. These lines supplied the divers with breathing air, reserve air, communication lines, lighting, video and data transmission, and water to flush the breathing regulators in the diving helmets. Those flange connections are also perfect for the new overpressure work helmet. The Diving Helmet

Diving helmets normally used for offshore diving were specially modified to allow them to be used for diving in bentonite. To make it easier for the divers to breathe in the bentonite, which is a clay suspension, and to reduce breathing resistance, the helmets were fitted with a water flushing system for the air regulator. The constant supply of fresh water also prevents the breathing membranes from sticking together.

The Umbilical

As the name indicates, the umbilical is the diver’s lifeline. The umbilical consists of a variety of differently coloured tubes and cables, which pipe in air, reserve air and fresh water, and also contain communication lines, light, video and data transmission lines.

Diving and Compressed Air Work in Saturation Conditions The Living Chamber Saturation diving means living and working under hyperbaric conditions for long periods of time, i.e. anything up to 28 days, although the limits have never been fully tested. To enable divers and engineers to survive and work under these conditions requires a pressurised living chamber consisting of a number of rooms outside of the tunnel zone. Up to 9 divers and engineers can live in this system, and it contains all the necessary facilities, from berths to showers and toilets.



The Transport Shuttle Due to technical and hygienic reasons, it is not as a rule feasible to locate the saturation habitat in the tunnel zone and link it to the tunnel machine. This makes it necessary to use a mobile transportation system – a shuttle. The shuttle collects the divers from the habitat outside the tunnel zone and takes them to the tunnel, where they dock on to the tunnel machine. Each pressurised shuttle can take up to 4 divers, technicians and engineers. Once it docks on to the tunnel machine, the passengers disembark and go to their stations in the control room and the

excavation chamber to carry out all necessary inspection, maintenance and repair work to the cutterhead. The NEW Technology 2012/2013

Lake Mead (USA) and Nanjing Weisan Tunnel Project (China) The new Mixed-Gas-Saturation Generation is designed and manufactured by IHC Hytech from the Netherlands in co-operation with Nordseetaucher GmbH. Those mobile Systems are for overpressure up to 20bar. The containerised System can be installed on the TBM in the shaft and/or on the surface.

The diver/technicians will be transported from the Living Chamber into the tunnel and on the TBM with a special designed Shuttle and Lifting System. Since September 2013 the designed new Mixed-Gas-Saturation System is busy in Nanjing-China on the TBM of CCCC-China Communication Construction Company.



The Hyperbaric Helmet Unlike in the 4th Tube of the River Elbe Tunnel and Wesertunnel projects, where the pressure was in excess of 4.5 and 5.0bar, we were unable to work with compressed air under the Westerschelde. Instead, we used mixed gases, consisting of helium, nitrogen and oxygen. The equipment used by the divers was identical to that used in the other tunnel projects. Partially submerged work under the Westerschelde was carried out with the aid of a new, lightweight type of helmet used in the chemical industry.

These helmets, which are not available on the free market, were specially refitted and adapted for the task. All tests and trial runs prior to the start of the project were carried out at the Belgian Navy’s Hyperbaric Centre in Zeebrugge. This special helmet has two breathing regulators and a controllable cooling system, the latter being essential, as temperatures in front of the tunnel face can reach up to 50° Celsius. The NEW Technology 2012/2013

This new helmet design of Composite Beat Engel, Switzerland is the construction of an overpressure helmet. It has been realized in close co-operation with Nordseetaucher GmbH. This type of helmet - that with an additional kit can be transformed within one hour into a breathing controlled helmet - is now operational in extreme hazardous environment like tunnel machines and gives full satisfaction to the user. Every helmet is provided with connections for surface air/gas

supply, an independent emergency air/gas connection and communications equipment.



The Nanjing Yangtze River Crossing Tunnel is a 2.990 km long twin tube crosses the river Yangtze in Nanjing, China. Two Slurry-TBMs ( 14.96 m) are in use to excavate the tunnel in soft alluvium strata. The strata are mainly silt and fine sand. The tunnel invert’s deepest point is 65 m below sea level. Due to tidal influence the water level of the river is typically between +/-1.5 m

above/below sea level.

On this project, welding in compressed air was the major task to carry out. From our experience and research of welding in compressed air and under water we knew that it is not a real problem. But this time it was very extreme. The buckets of 6 arms of the TBM had to be renewed. Therefore we welded new supports on the side arms of the cutterhead. The total time of this work took more than 12 weeks, day and night. The pressure was up to 5.4 bar overpressure in air. To keep the support pressure stable we used bentonite with a special mixture of high density and viscosity.

Maintenance and repair under compressed air was performed at up to 5.4 bar air pressure for works at the cutterhead and up to 6.5 bar for works at the stone crusher. Regular compressed air (no mixed gases) and oxygen decompression is successfully in use. In total more than 4.000 h of compressed air works and more than 945 total man interventions are performed. Only 3 minor cases of decompression illness are reported.

For the welding operation we used the first time a new special designed compressed air helmet with triple air supply, two regulators and one free flow, communication and an integrated welding shield with sensors.



The Esfahan Metro Tunnel is a 4.550 km long twin tube between Shohada Aquare and Azadi Aquare. The west and the east tunnel crosses the river Zayandehrood in the south of Esfahan, Iran. The two EPB TBM’s ( 6.96 m) are in use to excavate the tunnel in soft alluvium strata. The strata are mainly silt, fine sand and gravel. The tunnel invert’s deepest point is 20 m below street level and river.

Welding in compressed air is the major task to carry out. But this time the job is more extreme. The 8 cutterhead arms of the TBM had to be renewed more or less completely from the front side and the cutterhead edge of both machines from the back side. Therefore we welded new vertical side plates and new cover plates on the arms of the cutterhead and new hardox plates on the cutterhead edge. The total time of this work will take more than 6 month, day and night. The pressure is up to 2.0 bar overpressure in air. To keep the support pressure stable we used bentonite with a special mixture of high density and viscosity.

Maintenance and repair under compressed air is performed at up to 2.0 bar air pressure for works at the cutterhead. Regular compressed air and oxygen decompression is successfully in use. In total more than 2.000 h of compressed air works and more than 375 man interventions until 31.03.2010 are performed. No minor case of decompression illness is reported.



Beijing Railway Tunnel ZJX – 2 Project



Project: S-636 Metro Hangzhou

Change of the Main Drive Sealing System at 2.1bar overpressure.

All 4 seals of the Main Drive Sealing System of a TBM were worldwide changed in overpressure in June 2012 for the first time. The unusual feature of this repair primarily consisted that the seals had to be changed, not like in the manufactory in a horizontal layer, in a vertical layer.

To make the dismantling and assembly work easier some grits were mounted in the excavation chamber, so that each place of the Main Drive Sealing System was attainable without problems. The dismantling of the faulty seals and the Chamber Rings was carried out by means of pulling-off devices made especially for it. Before the opening of the Main Drive Sealing System it was needed to clean the cutterhead and excavation chamber and suck out all material to make sure

that no pollutions be able to hinder the seal replacement. All chamber rings and the seal housing were cleaned from any dirt and grease with high pressure water and cold-cleaner. The new seals were volcanized with a special bonding device of Nordseetaucher. To ensure a one

hundred per cent connection, the device has been heated up to approximately 70 - 80 ° degrees Celsius for three hours. The correct situation of the single seals and chamber rings were measured before and after the mounting. The measurements record was made according the design plans, delivered by Herrenknecht AG.



Summary High groundwater pressure (above 4 bar) makes tunneling much more difficult and requires special knowledge of cutting edge technologies during design and construction. TBM, tunnel equipment and tunneling procedures should be designed to enable reliable application of adequate support pressures at all times during excavation and hyperbaric interventions to counterbalance the acting groundwater head. If adequate primary components and backup systems are not installed on the TBM, major problems including cost overruns and time delays can occur. Tunnel excavation in strong, fine grained cohesive soils and rock under high groundwater pressure is generally not problematic for Slurry- and EPB-TBMs, as typically the face is stable and the amount of inflowing water is low due to low permeability of the ground. In coarse-grained soil or unstable rock, tunnel excavation requires a reliable active face support to provide face stability and prevent excessive lost ground during tunneling and interventions. Suitable active face support is easier to achieve with Slurry-TBMs. Depending on the level of the groundwater pressure, abrasiveness of the ground and the length of the corresponding tunnel sections, the TBM should include provisions for hyperbaric interventions using regular compressed air, mixed gases or saturation diving, depending on pressure level and duration of intervention time expected. Only in very strong, low permeability soils or in competent rock are risks of attempting cutterhead interventions under free air reasonable (if not otherwise restricted), but there should always be provisions available to apply adequate compressed air support or ground treatment if needed. The experience gained in the projects proves that the saturation method is a very successful approach to hyperbaric tunnel constructions. It also shows us that work in compressed air is possible up to 6.5 bar overpressure, but not very efficient. The cooperation between the tunnel construction companies, the manufacturer of the TBM’s, the Herrenknecht AG, the Hyperbaric Medic Dr. Faesecke, the Hyperbaric Training Center, Germany, the Classification Company Germanischer Lloyd, the Design and Manufacture Company Composite Beat Engel and the Nordseetaucher GmbH is very rewarding and productive, and we hope that it can be intensified in future co-operations. The excellent training of the diving personnel, engineers and hyperbaric construction technicians involved in this ground-breaking projects, the continual training and the adaptation of the tunnelling machines to the existing conditions open up a highly promising perspective on the future of tunnel construction: deeper, larger and longer.



Requirements for Work in Compressed Air and Mixed Gas

Operation Pressure 0.7 – 3.0 bar Intervention

Method Required

Equipment on the TBM

Required Equipment

for Hyperbaric Works

Required Personal

Requirement at the Excavation

Chamber

Breathing Gas: Compressed Air

Work Method: Technician in

Compressed Air

Divers in Bentonite

Minimum

1 Air Lock equipped according to Compressed Air Regulation device

with O2 Decompression

Excavation Chamber with

double compressed air supply lines for

safety reasons

Compressed Air Breathing System for welding and

cutting

DN 300 mm Penetration Flanges for

diver/technician breathing gas,

monitoring, HP-Water and

Hydraulic supply

On the TBM: Front Gate & independent

regulation tank to regulate the excavation

chamber pressure during compressed

air work

Video Monitoring System

At the Surface: Compressed Air Station inclusive air cooler and air

filter

Compressed Air Supervisor

Compressed Air

Team: 1 Shift Supervisor

2 trained Technicians

changing the tools 1 trained

Technician in charge of material

handling and service

Surface Team:

1 Lock Attendant (chamber operator)

2 Service Technicians

Max. working time in compressed air

0,7 bar = > 4:00 hrs to

3,0 bar = 2:45 hrs _______

Hyperbaric

Doctor

Medical Advisor

Necessary to lower the level of

Bentonite under the location of the

tools to be changed,

to have free access to the excavation

chamber



Operation Pressure 3.1 – 5.0 bar Intervention

Method Required


Required Equipment


Required Personal


Chamber

Breathing Gas: Compressed Air

or Mixed Gas

Work Method: Technician in

Compressed Air

Divers in Bentonite

Minimum

2 Air Locks

equipped according to Compressed Air

and Mixed Gas Regulations

with O2 Decompression

Excavation

Chamber with double compressed air supply lines for

safety reasons

Compressed Air / Mixed Gas

Breathing System for welding and

cutting


diver/technician breathing gas, monitoring,

HP-Water and Hydraulic Supply




air work

Gas bottles for Mixed Gases Operations,

specific Hyperbaric Helmets for the

workers (see

Nordseetaucher document)

Video Monitoring

System

At the Surface: Compressed Air

station inclusive air cooler and air filter

Compressed Air

Mixed Gas Supervisor

Compressed Air

Team: minimum 2 shifts

1 Shift Supervisor

2 trained Technicians

changing the tools 1 trained

Technician in charge of material

handling and service

Surface Team:



Max. working time in Compressed Air 3,1 bar = >2:50 hrs

to 5,0 bar = 1:00 hrs

Mixed Gas 5,0 bar = 2:15

_______

Hyperbaric Doctor

Medical Advisor

Necessary to lower

the level of Bentonite under the

location of the tools to be changed,


chamber

For diving in Bentonite extra entrance door

below the centre in the lower area.

Not necessary to lower the level of

Bentonite



Operation Pressure > 5.0 bar Intervention

Method Required


Required Equipment


Required Personal


Chamber

Breathing Gas:

Mixed Gas

Work Method: Technician and

Divers in Mixed Gas

Divers in Bentonite

Entering in Semi-Sat and Saturation

Method

Minimum

2 Personnel Locks equipped according

to Sat-Diving Regulations

Excavation

Chamber with double compressed air supply lines for

safety reasons

Due to the long decompression time, specific

equipment at the surface

(see Nordseetaucher

report) are necessary

Mixed Gas

Breathing System for welding and

cutting


diver/technician breathing gas, monitoring,

HP-Water and Hydraulic Supply




air work

Gas bottles for Mixed Gases operations,

specific Hyperbaric Helmets for the

workers (see

Nordseetaucher report)

Video Monitoring

System

At the Surface: Compressed Air

station inclusive air cooler and air filter

Saturation Living

System 2x Transport

Shuttle (see

Nordseetaucher report)

Saturation Mixed Gas Supervisor

Team:

minimum 2 shifts

1 Shift Supervisor 2 trained

Technicians changing the tools

1 trained Technician in

charge of material handling and

service

Surface Team TBM:



Sat.-System Team

24 h Service on request

Max. working time

in Semi-Sat or Saturation: on request _______

Hyperbaric

Doctor

Medical Advisor

Necessary to lower

the level of Bentonite under the

location of the tools to be changed,


chamber

For diving in Bentonite extra entrance door

below the centre in the lower area.

Not necessary to lower the level of

Bentonite



Containerized Hyperbaric- and Diver Treatment Chamber with Spray Fog Fire Fighting System

Main Chamber Volume 6.800 l Ante Chamber Volume 3.100 l Material Mild Boiler Steel H II Number of Doors 3 pieces Rectangular Door (MC-direct access) 1500 mm x 600 mm Circular Door, free diameter (AC-direct / MC-AC) 700 mm Number of Windows in MC (Wall MC/AC and AC/MC door) 3 Window Free Diameter (cylinder wall + doors) 200 mm Supply Lock (MC-control-panel-side 1 free diameter 200 mm free length 300 mm volume approx. 9 l NATO/STANAG/DIN-Bayonet-Flange (female) for connection of Rescue Chamber 1 arranged at AC-access Electrical Connection 230/400 Volt 50 Hz Electrical Consumtion approx. 4000 Watt Certification German Lloyd Weight, chamber complete equipped approx. 14.500 kg

HAUX LIFE SUPPORT

Starmed 2000 / 5.5

Max. Design Pressure Max. Working Pressure Max. Test Pressure

Main Chamber Capacity Ante Chamber Capacity

Chamber Diameter Length of Main Chamber Length of Ante Chamber Length over all, incl. control panel Width over all Height over all, incl. illumination units

5,5 bar 5,0 bar 8,25 bar

3 seating or 2 lying persons 2 seating persons

2000 mm 2200 mm 1000 mm approx. 4000 mm approx. 2020 mm 2145 mm

Entrance and Control Panel Treatment Area to the Entrance

Treatment Area to the Ante Chamber



TUNNELDIVING CONTAINER

Pressure-Wall Flange: Flange Diameter NW 300 (460 x 40 mm) Flange Connection: 3 x 3/8“ LPAir Supply 3 x ¼“ Deapth Measurement 1 x 1” Water Supply 1 x 1” HP Air 3 x Communikation (Round Robin) 3 x Light 2 x Video 2 x Hydraulik Supply (in / out) 2x Power Supply Welding / Cutting

Diver Umbilical: 2 x 30 m Container – Flange 3 x 20 m Flange – Diver Diver Helmets: 2 x Kirby Morgan 27 / Composite DSL-D1 Diver Suits : 3 x Heavy Duty 3 x Harness + Weight 3 x Gloves

Container Datas: Length of Container 3,0 m Length over all 4,7 m Width over all 2,0 m Hight of Container 2,0 m Hight over all 2,25 m Container Equipment: 1 x 1 Compressor Draeger K 14 200/300 bar 4 x 50 Ltr. HP Air Storage 2 x 50 Ltr. HP Air Reserve 1 x Diver Panel 2 x Communication Round Robin 1 x Video System 1 x Air Test Unit 1 x Office Computer Spare Parts



Video Endoscope System Everest XL G3

A video probe should be always used if the compressed air technicians are unable to inspect the tools at the cutter head in complete safety.

The advanced, proven inspection technology of the XL G3 range of products enables you to inspect and measure the angle, depth and distance of all damage or objects precisely and safely. Images can be recorded, stored and retrieved for precise, seamless documentation. References: Herrentunnel Lübeck-Germany; Metro Linie 9 Barcelona-Spain; Pescanova Fish Farm, Mira-Portugal; CRCC Nanjing Yangtze River Crossing-China



and

presents

(Utility Model DE 20 2005 014 078)

Transfer Lock under Pressure

POBS - Portable Oxygen Breathing System

Oxygen Supply Hoses

Oxygen Dump Hoses

Med. Oxygen

The Oxygen Breathing Unit consists of the following components:

A hard case with a built-in mask connection panel Breathing masks A frame with a vacuum expiration assistance

system An oxygen pressure reducer Connection hoses

The Frame can be placed at a safe location to dump the exhaled oxygen. The frame is connected to the pressure chamber with a large diameter exhaust hose. The frame has an expiration assistance system.

To install the system at a pressure chamber, two hull penetrators and a 7-wire electrical connection are needed (minimum 1”)



Portable Oxygen distribution system for 3 masks includes:

- Heavy duty transport box, complete with integrated panel, consisting an aluminium anodized control panel, with line diagrams, pictograms, as well as 3 x inhalation and exhalation breathing regulators with a free flow adjustment knob, all with inhalation and exhalation isolation valves.

- The interface hoses between the oxygen inlet and the oxygen outlet system, length each hose 3

meters, and complete with phosphor bronze swaged fittings.

- The chamber wall penetrations with control valves

- Oxygen inhalation and exhalation hoses with a length of 45 meters

- 1 x high pressure oxygen regulator; 1 x oxygen BIBS vacuum controller; 1 x low pressure reducer in the control panel

- Exhaust vacuum system which makes it possible to exhale at shallow depths, and this exhaust

vacuum control system will be installed in an ABS heavy duty transport case (identical to the oxygen panel which is used for the portable oxygen control panel)

- All quick connectors on the oxygen control- as well as vacuum panels-, as well as on the hoses-,

will be provided with blind caps/protective caps All fitted together to a full working system. The breathing masks to be connected to the portable oxygen system

- We supply “Sea Long” resuscitation masks with a soft wearing comfort, better than the most

other masks on the market.

- The mask comes complete with a 90 degrees hose adaptor, and the headgear.

- Also masks are designed for long term use, and can be disinfected easily. The communication system for the oxygen breathing masks:

- The technician wearing a throat microphone, which has to be mounted around the neck / throat, by means of a small rubber strap

The communication box:

- The communication box is a transportable box with handgrip, and front lid to be installed at the position of the lock attendant or supervisor.

- The communication box is provided with a 220 volt power supply, as well as a rechargeable

battery.

- Further the system is provided with volume controls, electrical connectors for the power leads running from the chamber to the diver communication box.

- The length of the connection cable between the man lock and the communication system is up to

45 meters, and will delivered complete with a electrical through hull penetrator, which has to be installed in the chamber wall.



Abrasive Cutting Underwater and in Tunnel Boring Machines

in co-opearation with

WASS - System (WasserAbrasivSuspensions Schneidverfahren) is an abrasive cutting system for cutting of concrete and steel, above and underwater as well as for cutting in nuclear power plants and tunnel boring machines. Technical Datas cutting pressure up to 1500 bar water flow 8-10 ltr./min abrasive (grit) consumption 1,3 kg/min cutting speed in steel is approx.: 50 mm thickness = 40 mm/min 180 mm thickness = 15 mm/min

cutting of concrete in a tunnel boring machine

The length to be cut was from 250° till 110°. The height to be cut was approx. 5 cm The depth to be cut was approx. 110 cm

The nozzles were mounted on top of the cutter head. The hose were connected to the tunnel pressure wall.



Air supply Breathing protection equipment The compressed air filter unit AF 1400 produces breathing air in compliance with international standards from every compressed air source. The unit is fully compatible with all breathing protection devices that run with compressed air. The device can supply breathing air for up to four persons. No electrical socket is required. Its weather-proof, shockresistant and conductive casing makes the AF 1400 ideal for all kinds of on-site applications. AEROTEST Simultan LP AEROTEST Simultan HP The Aerotest LP and HP are the standard low and high pressure Aerotest simultaneous kits.

Technical Data Transport case Weight approx 4.4 Ibs (2 kg) Supply Pressure Maximum 150 psi (10 bar) Flow 0.2 L/min and 4.0 L/min Detects Four Contaminants Oil, CO2, CO, H2O Vapor For use by Military, Chemical Industry, Pharmaceutical Industry, Medical Industry and Hospitals, Food Industry, Power Plants, Consultants and Contractors, Offshore Industries, Hyperbaric Tunnel Constructions

Technical Data Transport case Weight approx 6.6 Ibs (3 kg) Supply Pressure Maximum 4500 psi (300 bar) Adapters CGA 347 (female) connection to cylinder valve CGA 347 (male) connection to compressor/filling station (G 5/8" or INT) Flow 0.2 L/min and 4.0 L/min Detects Four Contaminants Oil, CO2, CO, H2O Vapor For Use By Petro-Chemical Industry, Power Plants, Ship Industry, Gas Industry, Utilities, Fire Brigades, Industrial Hygienists, Manufacturing, Pharmaceutical Industry, Diving Industry



Hyfex Fire Extinguishers

DNV Approved Easily handled Two sizes available Instant response Economica

Hyfex Hyperbaric Fire Extinguishers are DNV Approved. They are simple, easily handled, and have been designed to be fitted in hyperbaric diving and medical therapy chambers. They are available in two sizes to facilitate easy mounting and be appropriate in the different compartment sizes found in such hyperbaric systems. The 3-liter Hy-Fex Extinguisher will probably be found in air dive chambers, entry and transfer compartments and the 7,5-liter Hy-Fex will suit main living chambers and large treatment chambers. They are foam stored pressure type charged up to 133 bar, with a suitable chamber gas-usually helium. This gas provides plenty of overpressure required to force the water and AFFF mixture through the outlet nozzle, to give a strong jet of foam. The Hy-Fex units mainly comprise of one robust aluminium cylinder containing the foam mixture and pressurized gas. This is in contrast to the old fashioned and cumbersome two-cylinder extinguishers used in the past.

HY-FEX Model 7.5 Litre: Height 600 mm Diameter 150 mm Weight charged 12 Kg Cylinder volume 7,5 liters Foam discharge 50 liters Discharge time 50 seconds Discharge distance 6 m Effective discharge 99% Cylinder test pressure 200 bar Cylinder working pressure 133 bar Temperature rating -15° to +55°C Tested depth 450 MSW Chamber volume rated 14 m³



Anti leakage and gas delivery line safety IBEDA – GAS - STOP The anti leakage and gas delivery line safety is especially constructed for use with gases obtained from either cylinder or mains supply. Through the double hose system, where there is the possibility of hoses damage or loose connections, the gas stop provides absolute safety by preventing unintentional and unnoticed escape of liquid fuel gas.



DeepSea Lightweight Model DSL A-2 AIR This new helmet design of Composite Beat Engel, Switzerland is the construction of an overpressure helmet. It has been realized in close cooperation with Nordseetaucher GmbH. This type of helmet - that with an additional kit can be transformed within one hour into a breathing controlled helmet - is now operational in extreme hazardous environment like tunnel machines and gives full satisfactionn to the user.

For the welding operation we use the new special designed compressed air helmet with triple air supply, two regulators and one free flow, communication, camera and an integrated welding shield with sensors.

This new helmet design of Composite Beat Engel, Switzerland is the construction of an overpressure helmet. It has been realized in close cooperation with Nordseetaucher GmbH. This type of helmet - that with an additional kit can be transformed within one hour into a breathing controlled helmet - is now operational in extreme hazardous environment like tunnel machines and gives full satisfaction to the user.



Research and Certification Because welding in compressed air becomes more and more interest in Caissons and Tunnel Boring Machines, Nordseetaucher GmbH has started in the beginning of the year 2010 a research and training program in co-operation with the Germanischer Lloyd, Germany and some manufacturer for welding electrodes and wires. The Hyperbaric Chamber for Research and Training Outside Inside Divers and Compressed Air Technicians who has gone through the training program successfully receives a certificate as a Professional Certified Hyperbaric Welder.

NORDSEETAUCHER GmbH - tunneltrade · NORDSEETAUCHER GmbH (N-Sea-Divers) Hyperbaric Tunnel...

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